S7-PLCSIM V5.3 incl. SP1

Transcription

1 SIMATIC S7-PLCSIM V5.3 incl. SP1 User Manual Edition: 01/2005

2 Copyright and Safety Guidelines This manual contains notices which you should observe to ensure your own personal safety, as well as to protect the product and connected equipment. These notices are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger: Danger Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Warning Indicates a potentially hazardous situation that, if not avoided, could result in death or severe injury. Caution Used with the safety alert symbol indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. Caution Used without the safety alert symbol indicates a potentially hazardous situation that, if not avoided, may result in property damage. Notice Used without the safety alert symbol indicates a potential situation that, if not avoided, may result in an undesirable result or state. Qualified Personnel The device/system may only be set up and operated in conjunction with this manual. Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are defined as persons who are authorized to commission, to ground, and to tag circuits, equipment, and systems in accordance with established safety practices and standards. Correct Usage Note the following: Caution This device and its components may only be used for the applications described in the catalog or the technical descriptions and only in connection with devices or components from other manufacturers that have been approved or recommended by Siemens. This product can only function correctly and safely if it is transported, stored, set up, and installed correctly, and operated and maintained as recommended. Trademarks Siemens and SIMATIC are registered trademarks of SIEMENS AG. STEP 7 and S7 are trademarks of SIEMENS AG. Copyright Siemens Energy & Automation, Inc All rights reserved The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. Disclaimer of Liability We have checked the contents of this manual for agreement with the hardware and software described. Because deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed. Siemens Energy & Automation, PCbA One Internet Plaza Johnson City, TN , USA Siemens Energy & Automation, Inc Technical data subject to change.

3 Preface S7-PLCSIM allows you to simulate the operation of an S7 programmable logic controller. You can test control programs from S7-PLCSIM without connecting to S7 hardware. S7-PLCSIM provides a graphical user interface for viewing and modifying control program variables, running the simulated PLC in single or continuous scan mode, and changing the operating mode of the simulated controller. Audience This manual is intended for engineers, programmers, and maintenance personnel who have knowledge and experience with S7 programmable logic controllers and STEP 7 programming. Scope This document describes the features and the operation of S7-PLCSIM V5.3 incl. SP1. Other Manuals You can find additional information in the online help for STEP 7 and in the following manuals: Programming with STEP 7 Manual. This manual provides basic information on designing and programming control programs. Use this manual when creating a control program with the STEP 7 automation software. System Software for S7-300/400 System and Standard Functions Reference Manual. This manual provides you with descriptions of the system functions, organization blocks, and standard functions that you use when developing a control program. Working with STEP 7 Getting Started Manual. This manual explains how to use the STEP 7 automation software. This manual provides you with an overview of the procedures used to configure a PLC and to develop control programs. To find these and other manuals, select the Start > Simatic > Documentation menu command from the Start menu of the computer where STEP 7 is installed. Additional Assistance North America and South America Europe and Africa Asia and Pacific region Telephone: +1 (800) Telephone: +49 (0) Telephone: Fax: +1 (423) Fax: +49 (0) Fax: simatic.hotline@siemens.com adsupport@siemens.com adsupport.asia@siemens.com iii

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5 Contents Product Overview...1 S7-PLCSIM Features... 1 Getting Started... 4 Differences from a Real S7 PLC... 5 S7-PLCSIM Simulation View Window... 7 CPU Operating Modes... 7 CPU Indicators... 8 Memory Areas... 8 Simulation Tasks...9 Starting the Simulation... 9 Using Help Help Buttons Options Button Menu Commands Help Browser Tabs Opening a Simulated PLC Opening a Layout Selecting Scan Mode Options Changing CPU Operating Modes Monitoring the Simulated Program Using the Slider Control Using S7-PLCSIM to Debug Your Program Using Interrupt OBs in Your Program Resetting the CPU Memory Resetting Timers Cycling Power for a Simulated CPU Using Symbolic Addressing Configuring an MPI Address Using Record/Playback Monitoring the Scan Cycle Saving a Layout Saving a Simulated PLC Closing a Simulated PLC Ending the Simulation Session Simulating a CPU 317-T View Objects...23 CPU View Object ACCUs & Status Word View Object Block Regs View Object Stacks View Object v

6 Contents Input Variable View Object Output Variable View Object Bit Memory View Object Timer View Object Counter View Object Generic Variable View Object Vertical Bits Variable View Object Error and Interrupt OBs...29 Hardware Interrupt (OB40-OB47) I/O Redundancy Error (OB70) CPU Redundancy Error (OB72) Communication Redundancy Error (OB73) Time Error (OB80) Diagnostic Interrupt (OB82) Insert/Remove Module Interrupt (OB83) Priority Class Error (OB85) Rack Failure (OB86) Reference Information...43 S7-PLCSIM Toolbars Standard Insert CPU Mode Record/Playback Files Toolbar Shortcut Key Combinations S7-PLCSIM Menus File Menu Edit Menu View Menu Insert Menu PLC Menu Execute Menu Tools Menu Window Menu Help Menu "What's This?" Help Button S7-PLCSIM Numeric Data Formats Troubleshooting Tips vi

7 Product Overview The S7-PLCSIM software enables you to run and test your program on a simulated programmable logic controller (PLC) that exists on your computer or programming device (such as a PG 740, Power PG or Field PG). Because the simulation exists completely within the STEP 7 software, you do not need to be connected to any S7 hardware (CPU or I/O modules). With the simulated S7 PLC, you can test and debug programs for S7-300, S7-400, and WinAC 3.x controllers. S7-PLCSIM does not support the hardware configuration for WinAC 4.x controllers; however, you can test your WinAC 4.x control program logic if you modify your hardware configuration to use an S7-300, S7-400, or WinAC 3.x controller. S7-PLCSIM provides a simple interface for monitoring and modifying different parameters used by the program (such as for turning inputs on and off). You can also use the various applications of the STEP 7 software while you are running your program on the simulated PLC. This allows you to use such tools as the variable table (VAT) to monitor and modify variables. S7-PLCSIM Features S7-PLCSIM simulates an S7 controller and contains the following memory areas: Memory Area Description Timers T 0 to T 2047 Memory bits Total addressable I/O memory Process image (setable; updated every scan) 131,072 bits (16 Kbytes) of M memory 131,072 bits (16 Kbytes) of I/O memory Maximum: 131,072 bits (16 Kbytes) Preset: 8192 bits (1024 bytes) Local data (setable) Maximum: 64 Kbytes Preset: 32 Kbytes Logic blocks and data blocks System function blocks (SFBs) 2048 function blocks (FBs) and functions (FCs) 4095 data blocks (DBs) SFB0, SFB1, SFB2, SFB3, SFB4, SFB5, SFB8, SFB9, SFB12, SFB13, SFB14, SFB15, SFB16, SFB19, SFB20, SFB21, SFB22, SFB23, SFB32, SFB33, SFB34, SFB35, SFB36, SFB37, SFB41, SFB42, SFB43, SFB44, SFB46, SFB47, SFB48, SFB49, SFB52, SFB53, SFB54, SFB60, SFB61, SFB62, SFB63, SFB64, and SFB65 Note that SFB12, SFB13, SFB14, SFB15, SFB16, SFB19, SFB20, SFB21, SFB22, SFB23, SFB41, SFB42, SFB43, SFB44, SFB46, SFB47, SFB48, SFB49, SFB60, SFB61, SFB62, SFB63, SFB64, and SFB65 are NOPs (do not perform any operation). You do not need to modify a program that calls a NOP. 1

8 Product Overview System functions (SFCs) SFC0, SFC1, SFC2, SFC3, SFC4, SFC5, SFC6, SFC7, SFC8, SFC9, SFC10, SFC11, SFC12, SFC13, SFC14, SFC15, SFC17, SFC18, SFC19, SFC20, SFC21, SFC22, SFC23, SFC24, SFC25, SFC26, SFC27, SFC28, SFC29, SFC30, SFC31, SFC32, SFC33, SFC34, SFC35, SFC36, SFC37, SFC38, SFC39, SFC40, SFC41, SFC42, SFC43, SFC44, SFC46, SFC47, SFC48, SFC49, SFC50, SFC51, SFC52, SFC54, SFC55, SFC56, SFC57, SFC58, SFC59, SFC60, SFC61, SFC62, SFC64, SFC65, SFC66, SFC67, SFC68, SFC69, SFC72, SFC73, SFC74, SFC79, SFC80, SFC81, SFC82, SFC83, SFC84, SFC87, SFC90, SFC102, SFC103, SFC105, SFC106, SFC107, SFC108, SFC126, and SFC127 For SFC26 and SFC27, S7-PLCSIM supports only an input parameter of 0. Note that SFC7, SFC11, SFC12, SFC25, SFC35, SFC36, SFC37, SFC38, SFC48, SFC60, SFC61, SFC62, SFC65, SFC66, SFC67, SFC68, SFC69, SFC72, SFC73, SFC74, SFC81, SFC82, SFC83, SFC84, SFC87, SFC102, SFC103, SFC105, SFC106, SFC107, SFC108, SFC126, and SFC127 are NOPs (do not perform any operation). You do not need to modify a program that calls a NOP. Organization blocks (OBs) OB1 (free cycle) OB20 to OB23 (time-delay interrupt) OB40 to OB47 (hardware interrupt) OB56 (update interrupt) OB61 to OB64 (synchronous cycle interrupt) OB72 (CPU redundancy error) OB80 (time error) OB82 (diagnostic interrupt) OB84 (CPU hardware fault) OB86 (rack failure) OB88 (processing interrupt) OB100 (warm restart) OB102 (cold restart) OB122 (I/O access error) OB10 to OB17 (time-of-day interrupt) OB30 to OB38 (cyclic interrupt) OB55 (status interrupt) OB57 (manufacturer specific interrupt) OB70 (I/O redundancy error) OB73 (communication error) OB81 (power supply error) OB83 (insert/remove interrupt) OB85 (priority class error) OB87 (communication error) OB90 (background OB) OB101 (hot restart) OB121 (programming error) Note that OB55, OB56, OB57, OB61, OB62, OB63, OB64, OB81, OB84, OB87, OB88, and OB90 are NOPs (do not perform any operation). You do not need to modify a program that calls a NOP. 2

9 In addition, S7-PLCSIM provides the following features: Product Overview A button on the SIMATIC Manager turns the simulation on or off. Clicking on the simulation button opens the S7-PLCSIM software with its simulated CPU. When S7-PLCSIM is running, any new connection goes automatically to the simulated CPU. The simulated PLC runs programs intended for S7-300 or S7-400 CPUs, including the CPU 317-T. You can create view objects that allow you to access the input and output memory areas, accumulators, and registers of the simulated PLC. You can also access memory through symbolic addressing. You can choose to have the timers run automatically or set and reset them manually. You can reset timers individually or all at once. You can change the CPU operating mode (STOP, RUN, and RUN-P) as with a real CPU. In addition, S7-PLCSIM provides a Pause feature that allows you to halt the CPU momentarily without affecting the state of the program. You can use interrupt OBs with the simulated PLC to test the behavior of your program. You can record a series of events (manipulate input and output memory areas, bit memory, timers and counters) and play back your recording in order to automate program tests. You can use all of the STEP 7 tools to monitor and modify the activities of the simulated PLC, and to debug your program. Although the simulated PLC exists entirely in software (requiring no special hardware), STEP 7 works as if the simulated PLC were an S7 PLC, with few differences. 3

10 Product Overview Getting Started If you are new to S7-PLCSIM, the following procedures will help you get started. Simulation mode is available from the SIMATIC Manager, provided you don't have any existing connections to real PLCs. To begin using S7-PLCSIM, follow these steps: 1. Open the SIMATIC Manager. 2. Click or select the menu command Options > Simulate Modules. This action starts the S7- PLCSIM application and opens a CPU view object (with the default MPI address of 2). 3. From the SIMATIC Manager, navigate to the S7_ZEBRA example project. This project is supplied with the STEP 7 software, V 5.x and higher (project file name ZEN01_09_STEP7_Zebra). 4. Within the S7_ZEBRA example project, navigate to the "Blocks" object. (See the SIMATIC Manager online Help for an overview of STEP 7 objects.) 5. From the SIMATIC Manager, click or select the menu command PLC > Download to download the "Blocks" object to the simulated PLC. 6. At the prompt, "Do you want to load the system data?", choose No if you do not want to download a hardware configuration to the simulated PLC, or Yes in order to download a hardware configuration (for instance, in order to use clock memory). 7. From the S7-PLCSIM application, create additional "view objects" for monitoring information from the simulated PLC: Click or select the menu command Insert > Input Variable. The view object displays IB0 (Input Byte 0). Click or select the menu command Insert > Output Variable to insert a second view object, QB0 (Output Byte 0). Click or select the menu command Insert > Timer three times to insert three Timer view objects. Type 2, 3, and 4 (for Timers T 2, T 3, and T 4) in their respective text boxes, pressing the Enter key after each entry. 8. Select the PLC menu in S7-PLCSIM and verify that there is a bullet ( ) beside Power On. 9. Select the Execute > Scan Mode menu command and verify that there is a bullet ( ) beside Continuous Scan. 10. Put the simulated CPU in RUN mode by clicking either the RUN or RUN-P check box. 11. Click bit 0 of IB0, to simulate turning on input 0.0, and watch the effect on the timers and on QB Click or select the menu command File > Save PLC As... to save the current state of the simulated PLC as a new file. Using STEP 7 to Monitor Program Simulation You can also use the STEP 7 tools to monitor the simulation of your program, as follows: 1. When you have created the view objects (step 7, above), go to the SIMATIC Manager. 2. Click or select View > Online to switch to online mode. 3. Navigate to the "Blocks" object in the ZEBRA example project, and open FC1. This action invokes the "LAD/STL/FBD" application. 4. When the simulated CPU is in RUN mode and you have turned on bit 0 of IB0 (step 11, above), go to the "LAD/STL/FBD" application window and select Debug > Monitor to see the effect of these changes on the program. 4

11 Differences from a Real S7 PLC The simulated PLC provides the following features, which are not available in a real PLC: Product Overview The Pause command halts the simulated CPU and allows you to resume the execution of the program at the instruction where the program was halted. You can change the operating mode (RUN, RUN-P, and STOP) as you do with a real CPU. Unlike with a real CPU, however, putting the simulated CPU in STOP mode does not change the state of the outputs. Any change that you make with a view object immediately updates the contents of the memory location. The CPU does not wait until the beginning or end of the scan to update any changed data. Execution control options allow you to select how the CPU runs the program: o o Single Scan executes the program for one scan and then waits for you to start the next scan. Continuous Scan executes the program like a real PLC: it starts a new scan immediately after the previous one finishes. You can allow the timers to run automatically, or you can enter timer values manually. You can also reset timers globally or individually. You can manually trigger the interrupt OBs: OB40 to OB47 (hardware interrupt), OB70 (I/O redundancy error), OB72 (CPU redundancy error), OB73 (communication redundancy error), OB80 (time error), OB82 (diagnostic interrupt), OB83 (insert/remove module), OB85 (program sequence error), and OB86 (rack failure). Process image and peripheral memory: When you make a change to a process input value in a view object, S7-PLCSIM copies it immediately to peripheral memory. This way, when the peripheral input value is written to the process image register at the beginning of the next scan, the desired change is not lost. Correspondingly, when you make a change to a process output value, it is copied immediately to peripheral output memory. The following diagram illustrates the order of activities in the scan cycle: 5

12 Product Overview S7-PLCSIM also differs from a real PLC in the following ways: Diagnostic buffers: S7-PLCSIM does not support all of the error messages written to the diagnostic buffer. For instance, bad batteries in the CPU or EEPROM errors cannot be simulated. However, most I/O and program errors can be simulated. A transition in operating mode (such as from RUN to STOP) does not change the I/O to a "safe" state. Function modules (FMs) are not supported. Peer-to-peer communication (such as between two S7-400 CPUs in the same rack) is not supported. S7-PLCSIM supports four accumulators like an S7-400 CPU does. For certain special cases, a program running on S7-PLCSIM with four accumulators can have different behavior from the same program running on an S7-300 CPU, which uses only two accumulators. S7-PLCSIM does not support forcing variables. Differences with I/O Most of the CPUs in the S7-300 family autoconfigure I/O: once a module has been inserted into a physical controller, it is automatically recognized by the CPU. It is not possible to replicate the autoconfiguration feature with a simulated PLC. If you download a program to S7-PLCSIM from an S7-300 CPU that autoconfigures I/O, the system data does not include an I/O configuration. Consequently, when you use S7-PLCSIM with S7-300 programs, if you want to define which modules are supposed to be available to the CPU, you must first download a hardware configuration. To download a hardware configuration to S7-PLCSIM, you can create a project for one of the S7-300 CPUs that does not autoconfigure I/O, such as the CPU 315-2DP, CPU 316-2DP, or CPU Put a copy of your hardware configuration into this project and download the hardware configuration to S7-PLCSIM. Once you have done this, you can download program blocks from any of your S7 projects and the I/O will be handled correctly. 6

13 S7-PLCSIM Simulation View Window Product Overview The simulation view window of S7-PLCSIM includes the workspace, title bar, status bar, window controls, and S7-PLCSIM menus and toolbars. The S7-PLCSIM workspace is where you display different types of view objects to monitor and modify data in the simulated PLC. To open the simulated PLC, click on the Simulation On/Off button on the toolbar (menu command Options > Simulate Modules) in the SIMATIC Manager. S7-PLCSIM starts and loads a CPU view object for your simulated PLC. You can also create a new simulated PLC, or open one that you have previously saved. To create a new PLC for simulation, select the menu command File > New PLC. To open a previously saved PLC, select the menu command File > Open PLC. To get familiar with S7-PLCSIM, use the procedures described in Getting Started. CPU Operating Modes RUN-P mode The CPU runs the program, and you can change the program and its parameters. In order to use the STEP 7 tools for modifying any of the parameters of the program while the program is running, you must put the CPU in RUN-P mode. You can use the view objects created within S7-PLCSIM to modify any data used by the program. RUN mode The CPU runs the program by reading the inputs, executing the program, and then updating the outputs. By default, you cannot download any program or use the STEP 7 tools to change any parameters (such as input values) when the CPU is in RUN mode. If you have configured CiR (Configuration in Run) elements in your STEP 7 project, however, you can download the CiR objects in RUN mode. With the simulated CPU in RUN mode, you can use the view objects created within S7-PLCSIM to modify any data used by the program. STOP mode The CPU does not run the program. Unlike STOP mode for real CPUs, the outputs are not set to predefined ("safe") values but remain at the state they were in when the CPU changed to STOP mode. You can download programs to the CPU while the CPU is in STOP mode. Changing from STOP mode to RUN mode starts execution of the program from the first instruction. The CPU operating modes, the CPU indicators, and the Memory Clear/Reset button are all displayed on the CPU view object. You can set the CPU operating mode with the Key Switch Position command. You can pause execution of the simulated PLC program when the CPU is in RUN or RUN-P mode. 7

14 Product Overview CPU Indicators The CPU view object provides a set of indicators that correspond to the LED indicators on a real CPU: SF (system fault) alerts you that the CPU encountered a system error, causing a change in the operating mode. DP (distributed peripherals, or remote I/O) indicates the status of communication with distributed (remote) I/O. DC (power supply) indicates whether power to the CPU is on or off. RUN indicates that the CPU is in RUN mode. STOP indicates that the CPU is in STOP mode. Memory Areas You access data in the S7 PLC by addressing specific areas of memory. These areas perform specific functions: PI (peripheral input): provides direct access to the input modules. I (input): provides access to the process image of the peripheral inputs. These values are updated by the CPU at the beginning of every CPU scan cycle. PQ (peripheral output): provides direct access to the output modules. These values are updated by the CPU at the end of every CPU scan cycle. Q (output): provides access to the process image of the outputs. M (bit memory): provides storage for data used within the program. T (timer): provides storage for timers. C (counter): provides storage for counters. You can also access data stored in the data blocks (DBs). 8

15 Simulation Tasks Starting the Simulation You can use one of the following methods to start S7-PLCSIM: From the Windows Start menu, select the menu command Simatic > STEP 7 > S7-PLCSIM Simulating Modules. From the SIMATIC Manager toolbar, click the Simulation On/Off button or select the Options > Simulate Modules menu command. When the Simulation On/Off button is turned on in the Simatic Manager, any new connection goes automatically to the simulated PLC. Any program that you download goes to the simulated PLC if the MPI address of the simulated PLC matches that of the STEP 7 project containing the program. If you click the Accessible Nodes button, the Accessible Nodes window shows the node address for the simulated PLC that you have created. When the simulation button is turned off, any new connection goes to the real PLC. If you click the Accessible Nodes button, the Accessible Nodes window shows the network of real PLCs. After you start S7-PLCSIM, you can open a simulated PLC or monitor the simulated program. You can continue PLC simulation until you end the simulation session. Notes Simulation mode is not available if you have any existing connections to real PLCs. You can have only one simulated PLC active at a time. 9

16 Simulation Tasks Using Help You can access the S7-PLCSIM Help through the Help menu or in any of the following ways: To get Help about an object in the S7-PLCSIM window, click the Help button on the toolbar, and then click the object. To get help about any dialog or error message, click the Help button in the dialog or message box, or press F1. The Help window provides the following buttons, menu commands and tabs: Help Buttons Hide Button / Show Button: Toggles the display of the navigation area (Table of Contents, Index, and Search tabs). To reduce the overall size of the help window, you can hide the navigation area; when you are ready to view new topics, click the Show button to restore the navigation area. Back Button: If you have examined more than one topic, this button allows you to move back to the previous topic(s). Print Button: Allows you to send a selected topic, or an entire book, to any printer that you have installed. Options Button Menu Commands Hide Tabs / Show Tabs: Toggles the display of the Table of Contents, Index, and Search tabs. To reduce the overall size of the help window, you can hide the tabs; when you are ready to search for new topics, you can show the tabs. Back: If you have examined more than one topic, this option allows you to move back to the previous topic(s). Forward: If you have moved back in the sequence of topics examined, this option allows you to move forward until you reach the topic that you were viewing when you started moving back. Home: Takes you to the web page that is defined as the home page for the S7-PLCSIM online help. Stop: Allows you to stop the browser from retrieving any more information pertaining to the current help page. This command is useful if a page contains a great deal of information (for example, large graphic files) that causes the page to take a long time to display completely. Refresh: Refreshes the display of the current help page. Internet Options: Allows you to define options for Internet browsing. Print: Allows you to send a selected topic, or an entire book, to any printer that you have installed. Search Highlight Off / Search Highlight On: Toggles the display of highlighting for topics that contain a term that you have specified in the Search field. The highlighting enables you to see exactly where in a given topic the term appears. Help Browser Tabs Contents Tab: Choose this tab to view the table of contents for the help system. Double-click any book icon to expand it and view the topics that it contains. Index Tab: Choose this tab to view an alphabetical list of index keywords for the help system. Search Tab: Choose this tab and type in a term that you wish to find. Double-click a topic from the list to view the topic. By default, the term is highlighted every place that it appears in the topic to make it easy to locate the term. To toggle highlighting off or on before displaying a topic, use the Options button. 10

17 Opening a Simulated PLC Simulation Tasks When you start S7-PLCSIM, the simulator opens with a new, untitled, simulated PLC. If this is your first time using S7-PLCSIM, you see only a CPU view object; otherwise, S7-PLCSIM displays the view objects from your previous work session. At this point, you have two choices: You can begin work in S7-PLCSIM using the new simulated PLC. You can open a simulated PLC that you have previously saved: use either the File > Recent Simulation command or the File > Open PLC command to select the appropriate.plc file. The work that you did with this PLC (such as downloading a program or hardware configuration, or assigning values through a view object) is saved in the archived simulation, so when you open the simulation, you do not have to repeat those steps. You can begin work where you left off the last time. After you decide whether to work with a new or an archived PLC simulation, you can add or change the view objects displayed in S7-PLCSIM. If a layout is displayed when you open S7-PLCSIM, you can close it. You can use the toolbar or the View and Insert menus to add new view objects. You can use the menu command File > Open Layout to select a different layout if you have archived more than one layout. Changes to your layout do not cause changes to your program information; they only affect the way that the information is displayed. Note When you open a new or archived PLC simulation, any view objects that were displayed in S7-PLCSIM are automatically closed. If you intend to open an archived layout as well as a new or archived PLC simulation, open the simulated PLC before opening the layout. What Is the Difference between a.plc File and a.lay File? A.PLC file is used to save information about work that you do with a CPU view object (that is, a simulated PLC). It also records changes you make to data: if you assign a value to a memory area using any view object, that change is saved in the.plc file. A.LAY file is used to save the physical layout of your workspace in S7-PLCSIM. If you arrange your view objects in a certain order and want to preserve that order for future work sessions, save the layout before you close S7-PLCSIM. The next time you open S7-PLCSIM, the view objects will be displayed in that order. (However, if you open a new or archived PLC simulation during that work session, S7-PLCSIM automatically closes your layout. If you want to use the same layout with the simulated PLC that you have opened, just re-open the.lay file.) 11

18 Simulation Tasks Opening a Layout To open a previously saved layout of S7-PLCSIM view objects, select the menu command File > Open Layout. A layout is simply an arrangement of view objects. In other words, the.lay file archives only the position and selected data format of the view objects in your simulation; the data values that are displayed in the view objects are not saved as part of the layout. When you work in S7-PLCSIM, you can open both a.plc file and a.lay file (if you have previously saved your simulated PLC and the layout of your view objects). These are not mutually exclusive actions; you do not have to choose only one. However, it is more efficient to open the simulated PLC (.PLC file) before the layout (.LAY file), because any time you open a new or archived PLC simulation, S7-PLCSIM automatically closes the open layout. You can also save a layout, save a simulated PLC, and close a simulated PLC. Selecting Scan Mode Options S7-PLCSIM offers you options for running the simulated program: Single Scan: The CPU executes one scan and then waits for you to initiate another scan. Each scan consists of the CPU reading the peripheral inputs (PI), executing the program, and then writing the results to the peripheral outputs (PQ). The CPU then waits for you to run the next scan (using the Execute > Next Scan menu command or ). Continuous Scan: The CPU executes one complete scan and then starts another scan. Each scan consists of the CPU reading the peripheral inputs (PI), executing the program, and then writing the results to the peripheral outputs (PQ). To choose Single Scan mode, click or select the menu command Execute > Scan Mode > Single Scan. Accessing a program one scan at a time allows you to see the changes in each scan. While a real CPU can execute faster than the editor can display data, the S7-PLCSIM Single Scan option allows you to "freeze" the state of the program from scan to scan. To choose Continuous Scan mode, click or select the menu command Execute > Scan Mode > Continuous Scan. (The default setting is Continuous Scan.) Changing CPU Operating Modes You can change the operating modes for the CPU. The simulated PLC responds to changes in the operating mode just like a real PLC. The checkboxes on the view object of the simulated PLC show the current operating mode. To change the operating mode, click the desired checkbox or use the menu command Execute > Key Switch Position > [mode]. The CPU operating modes on the simulated CPU function like the key switch on a real CPU: if you use the STEP 7 tools to change the operating mode, or if the CPU automatically changes mode (for example, encounters an error condition that causes the CPU to change from RUN to STOP), the checkboxes on the simulated CPU view object do not change. The LED indicator changes, but not the key switch. This alerts you that the CPU operating mode changed, possibly because of some error in the program. 12

19 Monitoring the Simulated Program Simulation Tasks You can display different types of view objects that allow you to monitor and modify the program running in the simulated PLC. The following seven view objects are activated from the Insert menu: Input Variable: allows you to access the data stored in the process input (I) memory area. The default address is byte 0 (IB0). Output Variable: allows you to access the data stored in the process output (Q) memory area. The default address is byte 0 (QB0). Bit Memory: allows you to access the data stored in the bit memory (M) area. The default address is byte 0 (MB0). Timer: allows you to access the timers used by the program. The default timer is T 0. Counter: allows you to access the counters used by the program. The default counter is C 0. Generic: allows you to access any of the memory areas in the simulated CPU, including the data blocks (DBs) for the program. Vertical Bits: allows you to see the symbolic or absolute address of each bit and to monitor and modify data. The vertical bits variable view object can be used to show a bit representation of peripheral input and output variables, process image input and output variables, bit memory, and data blocks. You can also use symbolic addressing to address any of these view objects. The following three view objects are activated from the View menu: Accumulators: allows you to display the data in the different accumulators within the simulated CPU, as well as the status word and address registers. This view object displays four accumulator fields to accommodate the four accumulators of the S7-400 CPU. Programs for an S7-300 CPU use only two accumulators. Block Registers: allows you to display the contents of the data block address registers within the simulated CPU. It also displays the number of the logic block that is currently being executed and the number of the previous logic block, along with the number of the instruction (step address counter, or SAC) being executed. Stacks: allows you to display the data stored in the nesting stack and the master control relay (MCR) stack within the simulated PLC. You can also simultaneously monitor the program in the STEP 7 "LAD/STL/FBD" application: 1. In the SIMATIC Manager, click or select View > Online to switch to online mode. 2. Navigate to the "Blocks" object in the S7_ZEBRA example project, and open FC1. 3. The "LAD/STL/FBD" application displays the program that is being executed by the simulated PLC. Use the menu commands to view the status of the instructions. 13

20 Simulation Tasks Using the Slider Control The slider control allows you to simulate values that change gradually or have a specific range, such as analog values. You can use the slider control for the following view objects: Input Variable Output Variable Bit Memory You can access the memory area with either a memory address or a symbolic address. To specify a slider control for one of the variable view objects, you select a slider format representation from the Select Numeric Format drop-down list. You also select whether to represent the values as decimal (positive integers), integer (positive and negative integers), or real numbers. The selection options are determined by the size of the memory location being accessed: Byte (B): decimal Word (W): decimal and integer Double word (D): decimal, integer, and real You can use either the mouse or the arrow keys to change the position of the slider control indicator. Changing the position of the indicator changes the value of the variable stored in the memory location. You can also enter a specific value in the Value field. You can also configure a minimum and maximum value for the slider control. Selecting a range of values does not affect the values that can be stored in the variable: the minimum and maximum values affect only the values that can be entered or displayed by the slider control. Selecting a range of values provides the following benefits: You can simulate a specific range of values, for example, the range of values that would be generated by a specific analog module. By limiting the range of values between the minimum and maximum, you can provide better resolution for entering data with the slider. You can always enter an exact value in the Value field of the view object. To select a minimum value for the slider, select Min from the Display Value, Min, or Max drop-down list of the view object. Then, enter the numeric value for the minimum in the Min field. To select a maximum value for the slider, select Max from the Display Value, Min, or Max drop-down list of the view object. Then, enter the numeric value for the maximum in the Max field. Using S7-PLCSIM to Debug Your Program S7-PLCSIM provides the following features to help you debug your program: The Pause command halts the simulated CPU immediately and allows you to resume the execution of the program at the instruction where the program was halted. Any change that you make with a view object immediately updates the contents of the memory location. The CPU does not wait until the beginning or end of the scan to update any changed data. Execution control options allow you to select how the CPU runs the program: o Single Scan executes the program for one scan and then waits for you to start the next scan. o Continuous Scan executes the program like a real PLC; it starts a new scan immediately after the previous one finishes. 14

21 Using Interrupt OBs in Your Program Simulation Tasks You can use S7-PLCSIM to test how your program handles different interrupt OBs. S7-PLCSIM supports the following error and interrupt OBs: OB40 to OB47 (hardware interrupt) OB70 (I/O redundancy error) {417-H systems only} OB72 (CPU redundancy error) {417-H systems only} OB73 (communication redundancy error) {417-H systems only} OB80 (time error) OB82 (diagnostic interrupt) OB83 (insert/remove module) OB85 (priority class error) OB86 (rack failure) Use the menu command Execute > Trigger Error OB to select a specific OB, and enter the header information in the dialog box. When you click the "OK" or "Apply" button, the simulated PLC generates the appropriate event and runs the program in the associated OB. The OBs that are available to be triggered from the Trigger Error OB menu depend on the I/O configuration for the simulated PLC. Input/Output Considerations In order to simulate interrupt OBs, you must download a hardware configuration that contains your I/O. For some cases your I/O is automatically included in the system data that STEP 7 downloads to S7-PLCSIM; in other cases, you must modify the configuration to one that does. S7-300 CPUs S7-300 CPUs such as the CPU 315-2DP, CPU 316-2DP, and CPU download an I/O configuration; other CPUs autoconfigure the I/O to match the physical I/O installed in the rack. Projects already configured for one of the CPUs named above do not require modifications to the hardware configuration. For other CPUs, you must copy your hardware configuration and put the data into a project for a CPU that does not autoconfigure I/O, namely a CPU 315-2DP, CPU 316-2DP, or CPU project. When you download the I/O information from the project, you can simulate interrupt OBs in S7-PLCSIM (and S7- PLCSIM is also able to detect any I/O referencing errors that your program may contain). 15

22 Simulation Tasks Resetting the CPU Memory To reset the memory of the simulated CPU, select the menu command PLC > Clear/Reset, or click the MRES button on the CPU view object. This action resets the memory areas, deletes the program blocks, and deletes the hardware configuration of the simulated PLC. When you perform a memory clear/reset, the CPU automatically goes to STOP mode and all existing connections to the module are disconnected. Resetting Timers The Reset Timers dialog allows you to reset any or all of the timers used in your program to their default values. You can select "All Timers" to reset all of the timers in the program or you can select specific timers to reset. To reset all of the timers in your program, use the Reset Timers toolbar button. To reset an individual timer, use the Reset Timers button on the timer view object for the specific timer. Cycling Power for a Simulated CPU Select the PLC > Power On and Power Off menu commands to simulate turning power on and off to the CPU. Using Symbolic Addressing To use symbolic addressing in your simulated program: 1. Select the menu command Tools > Options > Attach Symbols. This menu command invokes a dialog. 2. Browse to the STEP 7 symbol table to be referenced. 3. Click the OK button. 4. Create view objects for variables that you want to address symbolically. 5. To turn on symbols for all view objects, select the menu command Tools > Options > Show Symbols. To hide the symbols, select the command again. For the Vertical Bits view object, bit values are displayed vertically, and the symbolic or absolute address is displayed beside each bit. For all other view objects, symbol tooltips are available for the address fields. Point to a field with the mouse to see its symbolic address and comment (separated by a colon) in a tooltip box. Configuring an MPI Address Use the MPI Address dialog box (menu command PLC > MPI Address) to configure the simulated PLC for a specific network node address. The new address is stored with the configuration of the simulated PLC when you use the Save PLC or Save PLC As menu command. Ensure that the node address for the offline program matches the node address for the program in the simulated PLC. When the Simulation On/Off button on the SIMATIC Manager toolbar is turned on, clicking the Accessible Nodes button shows you that the simulated PLC that is currently open. Note You cannot change the node address for the simulated PLC while you are using STEP 7 applications to monitor the program. Close these applications before changing the node address. 16

23 Using Record/Playback The Record/Playback dialog box allows you to record or play back a series of data changes. Simulation Tasks To access this window, do one of the following: Choose the Tools > Record/Playback menu command. Click the Record/Playback button. The key sequence Alt + F5 toggles the display of the Record/Playback toolbar button. This topic discusses the following subjects: How to Record or Play Back an Event File Troubleshooting Tips How to Record or Play Back an Event File Click the New Event File button to create a new event file. Click the Open Event File button to locate and open an existing event file. Click the Save Event File button to save the events that you have just recorded. Click the Play button to play back an existing recording of events. Click the Record button to begin recording a series of events. Use the view objects in your simulation to turn bits on and off or assign data values as desired. The recorder captures every change you make to memory areas. Click the Pause button to temporarily suspend recording or playback. The pause function is convenient because it allows you to pause the recording of events and resume later. If you need to perform some other activity (for instance, add new view objects or answer the telephone) before you are finished generating events, you can click Pause and thus avoid a long delay in your recording. Pause allows you to minimize the time lag between events as you record, in contrast to the Delta button, which affects the overall rate at which the recording is played back. Click the Stop button to stop recording, or playing back, events. The Delta button allows you to select a rate of speed before you play back a recording. Your selection affects the overall playback duration. However, if some events were recorded closer together, or further apart than others, the relative time intervals are preserved even as the overall playback time is reduced or increased by your Delta selection. There are two ways for you to confirm that you are successfully recording or playing back events: Check the status bar of the Record/Playback dialog box to see whether it is in Recording, Playing, or Idle mode. Watch the title bar of the Record/Playback dialog box. It should display a numeric value that increments each time you record or play back an event. 17

24 Simulation Tasks If you are satisfied with your recording, remember to save it by using the Save Event File button before you close S7-PLCSIM. Troubleshooting Tips Problem I tried to record events, but when I played them back, nothing happened. The Play button is de-activated and I cannot play back a recording. Solution Change the mode of S7-PLCSIM from STOP to RUN. You can record events in STOP mode provided that you had previously been recording in RUN mode. All events recorded in STOP mode have a Delta value of zero. Therefore, when you play back the recording, all of the events that you recorded during a single scan are displayed in such rapid succession that they appear to occur simultaneously. You must have an open event file before you can play back the recording of the events. Use the Open Event File button to select and open an event file. I recorded a series of events and then closed S7-PLCSIM. The next time I opened S7-PLCSIM, I could not find the events. If you close S7-PLCSIM without saving the recorded events in an event file, your work is lost. Use the Save Event File button to save your work before you close S7-PLCSIM. I recorded a series of events, but when I tried to play them back, nothing happened. Check the status bar of the Record/Playback dialog box to see what mode it is in. If it says Playing, watch the title bar to see when a numeric value appears. When events are played back, a counter in the title bar keeps track of how many have been played back. Note that if you start a recording but do not promptly begin to trigger events, the recorder captures the time lag. When you play back the recording, the first event will take an equally long time to occur. You can examine the event file to verify that in fact, your events have been properly recorded. You can adjust the playback speed of the recording by using the Delta button. I cannot remember which event file contains the sequence of events that I want to play back. You can use long, descriptive file names to help differentiate your event files. If necessary, you can use a text editor to examine your files and locate the one with the correct sequence. The default storage location for event files is C:\Siemens\PLCSIM\S7wsi\S7EVENTS. However, if you upgraded from version 3.0 or 4.0 of S7-PLCSIM, the default storage location is C:\Siemens\STEP7\S7wsi\S7EVENTS. 18

25 Simulation Tasks I changed a single bit, but when I played back my recording, the entire byte changed. I am trying to record events in Single Scan mode but the recorder does not function as I would expect. My event file contains German mnemonics even though that is not my selection in STEP 7. If an Input Variable, Output Variable, Bit Memory, Generic Variable, or Vertical Bits View Object shows only one bit (e.g., Q0.0, Bits), a bit change is recorded correctly as only a change in that particular bit. However, if the view object displays all eight bits (e.g., QB0, Bits), a change to a single bit is recorded as a change in byte value instead of a change in that bit only. Consequently, it becomes possible that during playback of the recording, other bits within the byte could be represented as changing (for instance, process flags or Boolean inputs), when in fact they would not be affected during operation of a real PLC. When recording events with the CPU view object in Single Scan mode, note the following: You cannot start a recording in Single Scan mode unless you click the Next Scan button to increment the scan count. The first event in your recording must have a Delta value of 1 or higher. The Delta value is based on the number of scan cycles that have occurred since the previous event (which in this case was when you clicked the Record button). However, if you are beginning the recording in Single Scan mode, no scan cycles have elapsed. You must increment the scan. When you record events in Single Scan mode, they have a Delta value of zero (because they are all occurring within the same scan). Therefore, when you play back the recording, all the events that you recorded during a single scan are displayed in such rapid sequence that they appear to occur simultaneously. To provide a discernable time lag between events, you would have to click the Next Scan button or switch between Continuous Scan mode and Single Scan mode for each event. Events are recorded with German mnemonics in S7-PLCSIM regardless of your STEP 7 selection. You can disregard this phenomenon. 19

26 Simulation Tasks Monitoring the Scan Cycle The menu command Execute > Scan Cycle Monitoring opens a dialog box that allows you to enable or disable scan cycle monitoring (watchdog timer) and set the maximum scan cycle monitoring time for the simulation. The maximum scan cycle time is the maximum time the process is allowed to take for one full scan cycle of the S7 user program in the OB1 and update of the relevant I/O. If this time is exceeded, the simulated PLC goes into STOP mode. Because program execution may be significantly slower in S7-PLCSIM than with an actual CPU (especially when other applications are running at higher priority), you can experience annoying timeouts. This dialog makes it possible for you to disable or extend the scan cycle monitoring without modifying the program for the target PLC. Note that this dialog does not reflect the monitoring time set in the hardware configuration, and any changes affect the simulation only. If "Enable Scan Cycle Monitoring" is selected, you can set the monitoring time to any value between 1 second (1000 ms) and 1 minute (60000 ms), inclusive. The default scan cycle monitoring time is ms. Saving a Layout To save the current layout of S7-PLCSIM view objects, select the menu command File > Save Layout. A layout is simply an arrangement of view objects. In other words, the.lay file archives only the position and selected data format of the view objects in your simulation; the data values that are displayed in the view objects are not saved as part of the layout. You can save both the layout (.LAY file) and the PLC simulation (.PLC file) when you work. They are not mutually exclusive. For information about what is archived if you save a PLC simulation (.PLC file), see Saving a Simulated PLC. 20